Workshop Manual L200

BASIC BRAKE SYSTEM Click on the applicable bookmark to selected the required model year

35A-2

BASIC BRAKE SYSTEM CONTENTS

35109000197

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3

Load Sensing Spring Length Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5

Load Sensing Proportioning Valve Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Disc Brake Pad Check and Replacement . . . . . 15

SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Front Disc Brake Rotor Check . . . . . . . . . . . . . . . 16 Brake Lining Thickness Check . . . . . . . . . . . . . . . 17

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brake Drum Inside Diameter Check . . . . . . . . . . 18

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 7

Brake Lining and Brake Drum Connection Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 10

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Brake Pedal Check and Adjustment . . . . . . . . . . 10 Stop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . . 11 Brake Booster Operating Test . . . . . . . . . . . . . . . . . 11 Check Valve Operation Check . . . . . . . . . . . . . . . 12 Brake Booster Vacuum Switch Check . . . . . . . . . . . . . . . . . . . 12

MASTER CYLINDER AND BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 LOAD SENSING PROPORTIONING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . 24

Brake Fluid Level Sensor Check . . . . . . . . . . . . . 13

REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 30

35A-3

BASIC BRAKE SYSTEM – General Information

GENERAL INFORMATION

35100010120

The brake system has high reliability and durability which maintains excellent braking performance and braking feeling. The main features are as follows. D A dual type master cylinder is equipped in all models. D Both a single type and a tandem type brake booster have been adopted.

D

The following type of brake have been adopted. Front: Floating caliper, 2-piston, ventilated disc brakes (V4-W43, V5-W43) or floating caliper, 1-piston, ventilated disc brakes (V4-S60, V5-S60) Rear: Leading-trailing type drum brake.

Items

2WD

2WD

4WD

4WD

Master cylinder I.D. mm

23.8

23.8

23.8

23.8

Brake booster effective dia. of power cylinder mm

230 205 + 230*

230 180 + 205*

205 + 230

180 + 205

Brake booster boosting ratio

5.0

5.0

7.0

7.0

Load sensing proportioning valve decompression ratio

0.15

0.15

0.15

0.15

Front brake disc effective dia. mm

200

200

222 228*

222 228*

Front brake wheel cylinder I.D. mm

60.3 42.9*

60.3 42.9*

60.3 42.9*

60.3 42.9*

Rear drum brake drum I.D. mm

254

254

270

270

Rear drum brake wheel cylinder I.D. mm

23.8

23.8

23.8

23.8

Rear drum brake lining thickness mm

4.7

4.7

4.7

4.7

NOTE *: Vehicles with ABS.

35A-4

BASIC BRAKE SYSTEM – General Information

CONFIGURATION DIAGRAM

Brake booster

Load sensing proportioning valve Rear brake

Front brake

Rear brake

Master cylinder Front brake

Brake booster

Rear brake

Load sensing proportioning valve

Master cylinder

Rear brake

Front brake

35A-5

BASIC BRAKE SYSTEM – Service Specifications

SERVICE SPECIFICATIONS

35100030119

Items

Standard value

Limit

Brake pedal height mm

176 – 181

–

Brake pedal free play mm

3–8

–

Brake pedal to floor board clearance mm

95 or more

–

When load sensing spring s ring length is 190 mm (when unladen)

3,625 (5,884)

–

5,390 (17,652)

–

When load sensing spring length is 215 mm (when laden)

14,393 (17,652)

–

When load sensing spring s ring length is 190 mm (when unladen)

4,309 (5,884)

–

6,074 (17,652)

–

When load sensing spring length is 215 mm (when laden)

16,310 (17,652)

–

189 – 193

–

Petrol-powered vehicles

0.65 – 1.05

–

Diesel-powered vehicles

1.00 – 1.40

–

Vehicle which brake booster of power cylinder is 180 mm and 205 mm in effective diameter

0.90 – 1.30

–

Vehicle which brake booster of power cylinder is 205 mm and 230 mm in effective diameter

0.70 – 1.10

–

Front disc brake pad thickness mm

10

2.0

Front brake disc thickness mm

24

22.4

2WD

–

0.08

4WD

–

0,06

Front disc brake drag force (tangential force of wheel mounting bolts) N

69 or less

–

Rear drum brake lining thickness mm

4.7

1.0

2WD

254.0

256.0

4WD

270.0

272.0

0.05

–

Load sensing proportioning valve output out ut pressure ressure kPa (Input pressure kPa)

2WD

4WD

Load sensing spring length mm Booster push rod to master Single brake booster cylinder piston clearance mm

Tandem brake booster

Front brake disc run-out mm

Rear drum inside diameter mm

Front hub end play mm

35A-6

BASIC BRAKE SYSTEM – Lubricants/Sealants/Special Tools

LUBRICANTS

35100040105

Items

Specified lubricant

Brake fluid

DOT3 or DOT4

Brake piston seal

Repair kit grease

Guide pin boot inner surface Lock pin boot inner surface Piston boot mounting grooves Brake piston boot inner surface Lock pin bush inner surface Piston cup surface Rear brake shoe and backing plate contact surface

Brake grease SAE J310, NLGI No.1

Auto adjuster assembly

SEALANTS

35100050108

Items

Specified sealant

Remarks

Vacuum switch

3M ATD Part No.8661 or equivalent

Semi-drying sealant

Shoe hold-down pin

3M ATD Part No.8513 or equivalent

Drying sealant

SPECIAL TOOLS Tool

35100060095

Number

Name

Use

MB990964 MB990520 MB990623

Brake tool set

Pushing-in of the disc brake piston Installation of drum brake wheel cylinder piston cup

BASIC BRAKE SYSTEM – Troubleshooting

TROUBLESHOOTING

35A-7 35100070081

Symptom

Probable cause

Remedy

Vehicle pulls to one side when brakes are applied a lied

Grease or oil on pad or lining surface

Replace

Inadequate contact of pad or lining

Correct

Auto adjuster malfunction

Adjust

Drum eccentricity or uneven wear

Repair or replace as necessary

Low or deteriorated brake fluid

Refill or change

Air in brake system

Bleed air

Overheated brake rotor due to dragging of pad or lining

Correct

Insufficient braking power

Inadequate contact of pad or lining Brake booster malfunction Clogged brake line Replace

Grease or oil on pad or lining surface Load sensing proportioning valve malfunction

Increased pedal stroke (Reduced pedal edal to floor board clearance)


Adjust

Air in brake system

Bleed air

Worn lining or pad

Replace

Broken vacuum hose Faulty master cylinder Brake fluid leaks

Correct


Adjust

Excessive push rod to master cylinder clearance Brake drag

Correct

Incomplete release of parking brake Clogged master cylinder return port

Adjust

Incorrect parking brake adjustment Improper push clearance

rod

to

master

cylinder

Faulty master cylinder piston return spring

Replace

Worn brake pedal return spring Broken rear drum brake shoe to shoe spring Lack of lubrication in sliding parts

Lubricate

35A-8

BASIC BRAKE SYSTEM – Troubleshooting

Symptom

Probable cause

Insufficient parking brake function Worn brake lining or pad

Remedy Replace

Grease or oil on lining or pad surface Parking brake cable sticking Stuck wheel cylinder or caliper piston

Scraping or grinding noise when brakes are applied a lied

Excessive parking brake lever stroke

Adjust the parking brake lever stroke or check the parking brake cable routing


Adjust

Worn brake lining or pad

Replace

Caliper to wheel interference

Correct or replace

Dust cover to disc interference Bent brake backing plate Cracked drums or brake disc Squealing, groaning or chattering noise when brakes are applied

Disc brakes – Missing or damaged brake pad anti-squeak shim

Replace

Brake drums and linings, discs and pads worn or scored

Correct or replace

Improper lining parts Disc brake – Burred or rusted calipers

Correct or deburr

Dirty, greased, contaminated or glazed linings

Clean or replace

Drum brakes – Weak, damaged or incorrect shoe hold-down springs, loose or damaged shoe hold-down pins and springs

Correct or replace

Incorrect brake pedal or booster push rod

Adjust

35A-9

BASIC BRAKE SYSTEM – Troubleshooting Symptom

Probable cause

Remedy

Squealing noise when brakes are not applied

Bent or warped backing plate causing interference with drum

Replace

Drum brakes – Weak, damaged or incorrect shoe-to-shoe spring Poor return of brake booster, master cylinder or wheel cylinder Loose or extra parts in brakes

Retighten

Improper positioning of pads in caliper

Correct

Improper installation of support mounting to caliper body Improper machining of drum causing interference with backing plate or shoe

Replace drum

Disc brakes – Rusted, stuck

Lubricate or replace

Worn, damaged or insufficiently lubricated wheel bearings

Groaning, clicking or rattling noise when brakes are not applied

Incorrect brake pedal or booster push rod

Adjust

Stones or foreign material trapped inside wheel covers

Remove stones, etc.

Loose wheel nuts

Retighten

Disc brakes – Loose installation bolts Worn, damaged or dry wheel bearings

Lubricate or replace

Disc brakes – Failure of shim

Replace

Disc brakes – Wear on sleeve Incorrect brake pedal or booster push rod

Adjust

35A-10

BASIC BRAKE SYSTEM – On-vehicle Service

ON-VEHICLE SERVICE

35100090131

BRAKE PEDAL CHECK AND ADJUSTMENT Stop lamp switch

Operating rod

Stop lamp switch lock nut

Operating rod lock nut

BRAKE PEDAL HEIGHT 1. Turn back the carpet etc. under the brake pedal. 2. Measure the brake pedal height as illustrated. If it is not within the standard value, adjust as follows. Standard value: 176 – 181 mm (From the surface of melting seat to the face of pedal pad) (1) Disconnect the stop lamp switch connector, loosen the lock nut, and move the stop lamp switch to a position where it does not contact the brake pedal arm. (2) Adjust the brake pedal height by turning the operating rod with pliers (with the operating rod lock nut loosened). (3) Screw in the stop lamp switch until it contacts the brake pedal stopper (just before brake pedal is caused to move), return the stop lamp switch 1/2 to 1 turn and secure with the lock nut.

Pedal down

Pedal up Lock nut

Outer case Lock nut

(4) Connect the connector of the stop lamp switch. (5) Check to be sure that the stop lamp is not illuminated with the brake pedal released. 3. Return the carpet etc.

0.5 – 1.0 mm

BRAKE PEDAL FREE PLAY With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range. Standard value: 3 – 8 mm If the free play exceeds the standard value, it is probably due to excessive play between the clevis pin and brake pedal arm. Check for excessive clearance and replace faulty parts as required.


35A-11

CREARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD 1. Turn back the carpet etc. under the brake pedal. 2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floorboard. Standard value: 95 mm or more (From the surface of melting seat to the face of pedal pad) 3. If the clearance is outside the standard value, check for air trapped in the brake line, clearance between the lining and the drum and dragging in the parking brake. Adjust and replace defective parts as required. 4. Return the carpet etc.

STOP LAMP SWITCH CHECK

No continuity

Continuity

35100890090

Connect a circuit tester to the stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. The stop lamp switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm from the outer case edge surface, and if there is continuity when it is released.

4 mm

Good

No good

BRAKE BOOSTER OPERATING TEST

35100100087

For simple checking of the brake booster operation, carry out the following tests: 1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is defective.

When engine is stopped

When engine is started

2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective.

35A-12


No good

Good

3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above three tests are okay, the booster performance can be determined as good. If one of the above three tests is not okay at last, the check valve, vacuum hose, or booster will be defective.

CHECK VALVE OPERATION CHECK

35100900113

1. Remove the vacuum hose. (Refer to P.35A-20.) Caution The check valve should not be removed from the vacuum hose.

Valve A Booster side

2. Check the operation of the check valve by using a vacuum pump.

Spring B Intake manifold side

Vacuum pump connection

Accept/reject criteria

Connection at the brake booster side (A)

A negative pressure (vacuum) is created and held.

Connection at the intake manifold side (B)

A negative pressure (vacuum) is not created.

Caution If the check valve is defective, replace it as an assembly unit together with the vacuum hose.

BRAKE BOOSTER VACUUM SWITCH CHECK 35100920034 1. Connect an ohmmeter to the connector of the vacuum switch. 2. Start the engine and check for continuity when the vacuum hose is connected, and when it is disconnected. The vacuum switch is in good condition if there is no continuity when the vacuum hose is connected, and if there is continuity when it is disconnected. Body earth

BLEEDING

35100140102

Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. Specified brake fluid: DOT3 or DOT4


35A-13

MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) (1) Fill the reserve tank with brake fluid. (2) Keep the brake pedal depressed. (3) Have another person cover the master cylinder outlet with a finger. (4) With the outlet still closed, release the brake pedal. (5) Repeat steps (2)–(4) three or four times to fill the inside of the master cylinder with brake fluid.

3 (4)

BRAKE PIPE LINE BLEEDING Start the engine and bleed the air in the sequence shown in the figure.

1 Load sensing proportioning valve

2

4 (3) ( ): R.H. drive vehicles

BRAKE FLUID LEVEL SENSOR CHECK 35100910086

The brake fluid level sensor is in good condition if there is no continuity when the float surface is above “A” and if there is continuity when the float surface is below “A”. A

LOAD SENSING SPRING LENGTH CHECK 35100120021 AND ADJUSTMENT 1. Park the vehicle on a level ground. The vehicle should be unloaded and supported only by wheels. Caution Never support the vehicle with jacks or other similar means.

35A-14


Lever

A

Hole

Spring support

Standard value (A): 189 – 193 mm

A

3. If the spring length is not within the standard value, loosen the bolt attaching the support and adjust the distance by moving the support.

Stopper bolt

Pressure gauges

Load sensing proportioning valve

LOAD SENSING PROPORTIONING VALVE 35100130024 FUNCTION TEST 1. Connect pressure gauges to the input and output ports of the load sensing proportioning valve. 2. Bleed the system. (Refer to P.35-12, GROUP 35B – On-vehicle Service.)

3. Disconnect the spring at the support side. 4. Place the spring so that it is in parallel with the load sensing proportioning valve, and pull in the direction indicated by the arrow so that its length H shown in the figure (the length between its ends) is as noted below.

Stopper bolt

10 mm

2. While the lever of the load sensing proportioning valve is touching the stopper bolt, install the spring support so that the distance (A) from the edge of the spring mounting section of the lever to the place on the spring support shown in the illustration is at the standard value.

H Stopper bolt contact position

NOTE At this time the lever is pressed all the way to the load sensing proportioning valve.

Standard value: Items

Spring length H mm

Input fluid pressure kPa

Output fluid pressure kPa

2WD

190*1

5,884

3,625

4WD

17,652

5,390

215*2

17,652

14,393

190*1

5,884

4,309

17,652

6,074

17,652

16,310

215*2

NOTE *1 and *2 indicate the applicable lengths for unladen and laden vehicles respectively. 5. After making the check, install the spring. Disconnect the pressure gauges from the load sensing proportioning valve and bleed the air. (Refer to P.35A-12, GROUP 35B – On-vehicle Service.)

BASIC BRAKE SYSTEM – On-vehicle Service When new

When worn

Pad

DISC BRAKE PAD CHECK AND REPLACEMENT

35A-15 35100150129

NOTE The brake pads have indicators that contact the brake disc when the brake pad thickness becomes 2 mm, and emit a squealing sound to warn the driver.

Wear indicator

Brake disc

1. Check brake pad thickness through caliper body check port. Standard value: 10 mm Limit: 2.0 mm Caution 1. When the limit is exceeded, replace the pads at both sides, and also the brake pads for the wheels on the opposite side at the same time. 2. If there is a significant difference in the thicknesses of the pads on the left and right sides, check the sliding condition of the piston, lock pin and guide pin.

2. Remove the guide pin or lock pin . Lift the caliper assembly and retain with wire. Caution Do not wipe the special grease from the guide pin or lock pin . Do not contaminate the guide pin or lock pin .

3 2 4

1

3

3. Remove the following parts from caliper support. (1) Pad & wear indicator assembly (2) Pad assembly (3) Clip (4) Outer shim 4. Measure hub torque with pad removed to measure brake drag torque after pad installation. (Refer to P.35A-25.) 5. Install the pad and caliper assembly, and check the brake drag force. (Refer to P.35A-25.)

35A-16


FRONT DISC BRAKE ROTOR CHECK

35100270061

CAUTION When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked. Inspection items

Remarks

Scratches, rust, saturated lining materials and wear

D D

If the vehicle is not driven for a certain period, the sections of the discs that are not in contact with lining will become rusty, causing noise and shuddering. If grooves resulting from excessive disc wear and scratches are not removed prior to installing a new pad assembly, there will momentarily be inappropriate contact between the disc and the lining (pad).

Run-out or drift

Excessive run-out or drift of the discs will increase the pedal depression resistance due to piston knock-back.

Change in thickness (parallelism)

If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging.

Inset or warping (flatness)

Overheating and improper handling while servicing will cause inset or warping.

RUN-OUT CHECK AND CORRECTION 35100940016 1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust. 3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc.

Chalk mark

Limit: 0.08 mm 0.06 mm 4. If the run-out of the brake disc is equivalent to or exceeds the limit specification, change the phase of the disc and hub, and then measure the run-out again. (1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which run-out is greatest.

(2) For 4WD, place a dial gauge as show in the illustration, and then move the hub in the axial direction and measure the play. Standard value: 0.05 mm If the play is equal to or exceeds the standard value, adjust the wheel bearing preload. (Refer to GROUP 26 – Front Hub Assembly .)


35A-17

(3) If the play does not exceed the standard value specification, install the brake disc at a position 180_ away from the chalk mark, and then check the run-out of the brake disc once again. 5. If the run-out cannot be corrected by changing the phase of the brake disc, replace the disc or turn rotor with on the car type brake lathe (“MAD, DL-8700PF” or equivalent).

THICKNESS CHECK 35100160108 1. Using a micrometer, measure disc thickness at eight positions, approximately 45_ apart and 10 mm in from the outer edge of the disc. Brake disc thickness Standard value: 24 mm Limit: 22.4 mm Thickness variation (at least 8 positions) The difference between any thickness measurements should not be more than 0.015 mm. 2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the specification, replace the brake disc or turn rotor with on the car type brake lathe (“MAD, DL-8700PF” or equivalent).

BRAKE LINING THICKNESS CHECK

35100300135

1. Remove the brake drum. 2. Measure the wear of the brake lining at the place worn the most. Standard value: 4.7 mm Limit: 1.0 mm Replace the shoe and lining assembly if brake lining thickness is less than the limit or if it is not worn evenly. For information concerning the procedures for installation of the shoe and lining assembly, refer to P.35A-30. Caution 1. Whenever the shoe and lining assembly is replaced, replace both RH and LH assemblies as a set to prevent car from pulling to one side when braking. 2. If there is a significant difference in the thickness of the shoe and lining assemblies on the left and right sides, check the sliding condition of the piston.

35A-18

BASIC BRAKE SYSTEM – On-vehicle Service BRAKE DRUM INSIDE DIAMETER CHECK 35100320124

1. Remove the brake drum. 2. Measure the inside diameter of the brake drum at two or more locations. Standard value: 254.0 mm 270.0 mm Limit: 256.0 mm 272.0 mm 3. Replace brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalanced.

BRAKE LINING AND BRAKE DRUM CONNECTION CHECK

35100310138

1. Remove the brake drum. 2. Remove the shoe and lining assembly. (Refer to P.35A-30.) 3. Chalk inner surface of brake drum and rub with shoe and lining assembly. 4. Replace shoe and lining assembly or brake drums if there are any irregular contact area. NOTE Clean off chalk after check.

35A-19

BASIC BRAKE SYSTEM – Brake Pedal

BRAKE PEDAL

35100340182

REMOVAL AND INSTALLATION Post-installation Operation D Brake Pedal Adjustment (Refer to P.35A-10.)

30 Nm

6

11

22 Nm

1

14 Nm

8 2

5 9 8

3

10

4

7

Removal steps 1. Stop lamp switch 2. Brake pedal return spring 3. Split pin 4. Washer 5. Clevis pin 6. Brake pedal shaft bolt

7. 8. 9. 10. 11.

Brake pedal Bushing Pipe Pedal pad Pedal support member

35A-20

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster

MASTER CYLINDER AND BRAKE BOOSTER

35100370150

REMOVAL AND INSTALLATION Pre-removal Operation D Brake Fluid Draining

Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-12.) D Brake Pedal Adjustment (Refer to P.35A-10.)

5

5

5

15 Nm

1

1 8

4 15 Nm

7

11

6

2

14 Nm

11

10 3

1

9 15 Nm

Sealant: 3M ATD Part No.8661 or equivalent

Removal steps 1. Brake tube connection 2. Brake fluid level sensor connector 3. Master cylinder assembly "BA D Adjustment of clearance between brake booster push rod and primary piston 4. Vacuum switch connector "AA 5. Vacuum hose (with built-in check valve) 6. Split pin

7. 8. 9. 10. 11.

Washer Clevis pin Brake booster Sealer Vacuum switch

Caution Do not remove the check valve from the vacuum hose. If the check valve is defective, replace it together with the vacuum hose.


35A-21

INSTALLATION SERVICE POINTS "AA VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip.

"BA CLEARANCE ADJUSTMENT BETWEEN BRAKE BOOSTER PUSH ROD AND PRIMARY PISTON Calculate clearance A from the B, C and D measurements. A = B – C – D

C

D

Standard value: Brake booster size

Clearance A standard valve mm

Single brake booster

Petrol-powered vehicles

0.65 – 1.05

Diesel-powered vehicles

1.00 – 1.40

B

A

Measuring distance B

Measuring distance D

Tanden brake booster

Vehicle which brake booster 0.90 – 1.30 of power cylinder is 180 mm and 205 mm in effective diameter Vehicle which brake booster 0.70 – 1.10 of power cylinder is 205 mm and 230 mm in effective diameter

Block gauge

NOTE When brake booster negative pressure (petrol-powered vehicles: –66.7 kPa, diesel-powered vehicles: –93.3 kPa) is applied, clearance value will become 0.10 – 0.50 mm.

If the clearance is not within the standard value range, adjust by changing the push rod length by turning the screw of the push rod.

35A-22


MASTER CYLINDER DISASSEMBLY AND REASSEMBLY

35100420114

10

2 1 3 4

13

5

6

Master cylinder kit

7

14

11 2.5 Nm

11

12

8

8

9

13

10 13

12

12

14 Brake fluid: DOT3 or DOT4

AA"

Disassembly steps 1. Reservoir cap assembly 2. Reservoir cap 3. Diaphragm 4. Brake fluid level sensor 5. Float 6. Reservoir stopper bolt 7. Reservoir tank 8. Reservoir seal 9. Piston stopper bolt

AA"

10. 11. 12. 13. 14.

Gasket Piston stopper ring Primary piston assembly Secondary piston assembly Master cylinder body

Caution Do not disassemble the primary secondary piston assembly.

piston

and

DISASSEMBLY SERVICE POINT

Piston stopper ring

AA" PISTON STOPPER BOLT/PISTON STOPPER RING DISASSEMBLY Remove the piston stopper bolt and piston stopper ring while depressing the piston. Piston stopper bolt

INSPECTION D D D

35100430056

Check the inner surface of master cylinder body for rust or pitting. Check the primary and secondary pistons for rust, scoring, wear or damage. Check the diaphragm for cracks and wear.

BASIC BRAKE SYSTEM – Load Sensing Proportioning Valve

LOAD SENSING PROPORTIONING VALVE

35A-23 35100540018


Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-12.)

15 Nm

5 3

2 1 4

Removal steps 1. Spring holder "AA 2. Spring support 3. Brake tube connection 4. Load sensing spring 5. Load sensing proportioning valve

Lever

A

Spring support

A

Stopper bolt

Hole

Caution Do not disassemble the load sensing proportioning valve.

INSTALLATION SERVICE POINT "AA SPRING SUPPORT INSTALLATION While the lever of the load sensing proportioning valve is touching the stopper bolt, install the spring support so that the distance (A) from the edge of the spring mounting section of the lever to the place on the spring support shown in the illustration is within the standard value. Standard value (A): 189 – 193 mm

35A-24

BASIC BRAKE SYSTEM – Front Disc Brake

FRONT DISC BRAKE

35100600112


Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-12.)

90 Nm

3 15 Nm

1

15 Nm

4

2

90 Nm

3 1

4

15 Nm

2 90 Nm

Removal steps 1. Brake tube "AA 2. Front brake assembly 3. Brake hose bracket 4. Brake disc (Refer to GROUP 26 – Front Hub Assembly.)


35A-25

INSTALLATION SERVICE POINT "AA FRONT BRAKE ASSEMBLY INSTALLATION 1. Measure hub torque (A) with pad removed to measure brake drag torque after pad installation. 2. Securely attach the pad clip to the caliper support. Caution For the vehicles with 4WD, engage 2WD before measurement.

MB990520

3. Clean the piston and insert into cylinder with special tool. 4. Be careful that the piston boot does not become caught, when lowering the caliper assembly and install the lock pin. 5. Check brake drag torque as follows. (1) Start engine and hold brake pedal down for 5 seconds. (Pedal depression force: approx. 196 N) (2) Stop engine. (3) Turn brake disc forward 10 times.

(4) Check hub torque (B) with spring balance. (5) Calculate drag torque of the disc brake [difference between hub torque (B) and hub torque (A)]. Standard value: 69 N or less

6. If the brake drag torque exceeds the standard value, disassemble and clean the piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.

35A-26


DISASSEMBLY AND REASSEMBLY

35100620132

14

(Repair kit grease)

74 Nm

11

1

12 3 5

13

9

8 Nm

14 74 Nm

7

2 8 (Repair kit grease)

10

9

Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off.

8

5

6 (Repair kit grease)

Brake fluid: DOT3 or DOT4

4 3

5 9

1

13 8

7

14 13

4 6

Grease

9

11

3

5 6

2

12 10

Brake caliper kit

5

12 14

Pad repair kit

Caliper assembly disassembly steps "AA 1. Lock pin "AA 2. Guide pin 3. Bushing 4. Caliper support (pad, clip and shim) 5. Pin boot 6. Boot ring AA" 7. Piston boot AA" 8. Piston AB" 9. Piston seal 10. Caliper body

5

7

Seal and boots repair kit

Pad assembly disassembly steps "AA 1. Lock pin "AA 2. Guide pin 3. Bushing 4. Caliper support (pad, clip and shim) 11. Pad and wear indicator assembly 12. Pad assembly 13. Outer shim 14. Clip

35A-27

BASIC BRAKE SYSTEM – Front Disc Brake (Repair kit grease)

14

74 Nm

2 8 Nm

11

12

9 13

5 9 8

14

7

1

6

4

3 (Repair kit grease)

8 10 Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off.

5

(Repair kit grease)


14

5 2

11

4 3 8

5 7

6 14

Brake caliper kit

12

3

12 5

Pad repair kit

Caliper assembly disassembly steps "AA 1. Lock pin "AA 2. Guide pin 3. Bushing 4. Caliper support (pad, clip and shim) 5. Pin boot 6. Boot ring AA" 7. Piston boot AA" 8. Piston AB" 9. Piston seal 10. Caliper body

5

13

13

1

7

9

9

6

Grease

Seal and boot repair kit

Pad assembly disassembly steps "AA 1. Lock pin "AA 2. Guide pin 3. Bushing 4. Caliper support (pad, clip and shim) 11. Pad and wear indicator assembly 12. Pad assembly 13. Outer shim 14. Clip

35A-28

BASIC BRAKE SYSTEM – Front Disc Brake DISASSEMBLY SERVICE POINTS When disassembling the front disc brakes, disassemble both sides (left and right) as a set.

AA" PISTON BOOT/PISTON REMOVAL Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently.

AB" PISTON SEAL REMOVAL (1) Remove piston seal with finger tip. Caution Do not use a flat-tipped screwdriver or other tool to prevent damage to inner cylinder. (2) Clean piston surface and inner cylinder trichloroethylene, alcohol or specified brake fluid.

with

Specified brake fluid: DOT3 or DOT4

REASSEMBLY SERVICE POINT

"AA LOCK PIN/GUIDE PIN INSTALLATION Install the lock pin and guide pin to the caliper body as shown in the illustration.

Lock pin Guide pin

Guide pin

Lock pin

BASIC BRAKE SYSTEM – Front Disc Brake INSPECTION D D D D

35A-29 35100630104

Check cylinder for wear, damage or rust. Check piston surface for wear, damage or rust. Check caliper body or sleeve for wear. Check pad for damage or adhesion of grease, check backing metal for damage.

PAD WEAR CHECK Measure the thickness at the thinnest and worn area of the pad. Replace the pad assembly if pad thickness is less than the limit value. Standard value: 10 mm Limit: 2.0 mm Caution 1. Replace the pads always at both sides, and also the brake pads for the wheels on the opposite side at the same time. 2. If there is significant difference in the thicknesses of the pads on the left and right sides, check the sliding condition of the piston, lock pin and guide pin.

35A-30

BASIC BRAKE SYSTEM – Rear Drum Brake

REAR DRUM BRAKE

35100750091

REMOVAL AND INSTALLATION Pre-removal Operation D Loosening the Parking Brake Cable Adjusting Nut. D Brake Fluid Draining

18

Post-installation Operation D Brake Fluid Filling and Air Bleeding (Refer to P.35A-12 or GROUP 35B – On-vehicle Service.) D Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 – On-vehicle Service.)

19

10 Nm

15 Nm

3 2

11

15

4

14

16

13

12 8 7

5

6 17

1 10

8 7

6

9

17 16

4

17

: Sealant: 3M ATD Part No.8513 or equivalent

Specified grease: Brake grease SAE J310, NLGI No.1

Rear drum brake removal steps 1. Brake drum 2. Shoe-to-lever spring 3. Adjuster lever 4. Auto adjuster assembly 5. Retainer spring 6. Shoe hold-down cup 7. Shoe hold-down spring 8. Shoe hold-down cup 9. Shoe-to-shoe spring 10. Shoe and lining assembly 11. Shoe and lever assembly AA" "BA 12. Retainer

"AA 13. 14. 15. 16. 17.

Wave washer Parking lever Shoe and lining assembly Shoe hold-down pin Backing plate (Refer to GROUP 27 – Rear Axle Shaft.) Wheel cylinder removal steps 1. Brake drum 18. Brake tube connection 19. Wheel cylinder


35A-31

REMOVAL SERVICE POINT

Pin of shoe assembly

AA" RETAINER REMOVAL Use a flat-tipped screwdriver or the like to open up the retainer joint, and remove retainer.

Retainer

INSTALLATION SERVICE POINTS Washer

Shoe assembly

"AA WAVE WASHER INSTALLATION Install the washer in the direction shown in the illustration.

Pin

Parking lever

Pin of shoe assembly

Retainer

"BA RETAINER INSTALLATION Use pliers or the like to install the retainer or the pin positively.

35A-32


WHEEL CYLINDER DISASSEMBLY AND REASSEMBLY

35100770080

1

4

4

1 Grease

6 2 2 Brake fluid: DOT3 or DOT4

Grease: Repair kit grease

Wheel cylinder repair kit

5 8 Nm 6 1

3

4 2

Disassembly steps 1. Boots 2. Piston assembly "AA 3. Pistons "AA 4. Piston cups 5. Bleeder screw 6. Wheel cylinder body

2 4

3

1


35A-33

REASSEMBLY SERVICE POINT "AA PISTON CUP/PISTON REASSEMBLY (1) Use alcohol or specified brake fluid to clean the wheel cylinder and the piston. (2) Apply the specified brake fluid to the piston cups and the special tool.

MB990623

Specified brake fluid: DOT3 or DOT4 (3) Set the piston cup on the special tool with the lip of the cup facing up, fit the cup onto the special tool, and then slide it down the outside of the tool into the piston groove.

Piston

Caution In order to keep the piston cup from becoming twisted or slanted, slide the piston cup down the tool slowly and carefully, without stopping.

Have the lip facing upwards.

INSPECTION

35100780069

Check the piston and wheel cylinder walls for rust or damage, and if there is any abnormality, replace the entire wheel cylinder assembly.

NOTES

35A-1

BASIC BRAKE SYSTEM – General/Front Disc Brake

GROUP 35A

BASIC BRAKE SYSTEM GENERAL OUTLINE OF CHANGE D

The following service procedures have been established due to the changes of 16-inch 2-pot disc brake .

FRONT DISC BRAKE REMOVAL AND INSTALLATION Pre-removal Operation D Brake Fluid Draining

Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding

88 ± 10 N·m

3

4 15 ± 2 N·m

1

2

88 ± 10 N·m

Removal steps 1. Brake tube "AA 2. Front brake assembly 3. Brake hose bracket 4. Brake disc (Refer to ’97 L200 Workshop Manual GROUP 26 – Front Hub Assembly)

NOTE For service point, refer to the Basic Manual.

35A-2


DISASSEMBLY AND REASSEMBLY 14 15 1

11 7.9 ± 1.0 N·m Shim set

27 ± 4 N·m

Clip set

2 4 9

8 7

6

5

1 10

15 12 9

2

13 14

8 7

3 4 1

11 2 15

4 9 1

8

9 7

6

7 4

10 9 2

3

8

13

12 12

13

Grease

7

9 7

4

3 4 Brake caliper kit

AA" AA" AB"

Seal and boots kit

Caliper assembly disassembly steps 1. Bolt 2. Pin 3. Bushing 4. Pin boot 5. Caliper support, pad, clip and shim assembly 6. Caliper support 7. Piston boot 8. Piston 9. Piston seal 10. Caliper body 11. Bleeder screw

AC"

Pad set

Pad assembly disassembly steps 1. Bolt 2. Pin 3. Bushing 5. Caliper support, pad, clip and shim assembly 12. Pad and wear indicator assembly 13. Pad assembly 14. Outer shim 15. Clip


35A-3

LUBRICATION POINTS


9

Caution The piston seal inside the seal and boot kit is coated with a special grease, so do not wipe this grease off.




DISASSEMBLY SERVICE POINTS Clip

Caliper support

Refer to the Basic Manual except for service points described below. AC" HARNESS CONNECTOR REMOVAL Caution Swivel up the clip as shown to avoid deformation of the clip.

NOTES